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THEORY OF OPERATION
E-5 E-5
POWER WAVE 655/R
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NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
DC BUS BOARD, POWER BOARD,
FEED HEAD BOARD, GATEWAY
BOARD AND VOLTAGE SENSE
BOARD
The DC Bus Board receives approximately 65VDC
from the Bus Board rectifier. The DC Bus Board regu-
lates that 65VDC to a +40VDC supply. This regulated
40VDC is applied to the Feed Head Board, the
Ethernet/Gateway Board, the Power Board, and the
wire feeder receptacle.
The switching power supplies on the Power Board sup-
ply a variety of regulated DC voltages to the Control
Board. The Control Board uses these regulated volt-
ages to power the many circuits and communication
functions incorporated within the Control Board.
When the Feed Head Board activates the Voltage
Sense Board, the actual arc voltage is sensed (lead
67), and this information is delivered through the volt-
age sense board to the Control Board.
The Power Wave 655R uses two digital communication
platforms. Internally the PC boards communicate via
ArcLink. Externally the Power Wave 655R communi-
cates using the industry standard Ethernet or Device
Net protocol.The Ethernet/Gateway Board makes the
translation between the platforms possible. The Power
Wave 655R does not have a dedicated interface device
or board. The robot (or other input device – PLC, etc.)
acts as the user interface, issuing commands that are
translated by the Gateway Board to ArcLink compatible
messages. Figure E.5 depicts the flow of communica-
tion information.
FIGURE E-4 – DC BUS BOARD, POWER BOARD, FEED HEAD BOARD,
GATEWAY BOARD AND VOLTAGE SENSE BOARD
+
I
NPUT
BOARD
LEFT
SWITCH
BOARD
RIGHT
SWITCH
BOARD
INPUT
RECTIFIER
CR1
GATEWAY
BOARD
DC
BUS
BOARD
FEED
HEAD
BOARD
POWER
BOARD
CONTROL
BOARD
OUTPUT
CHOKE
ELECTRODE
TERMINAL
T
HERMOSTATS
T
1
T2
AUX
RECONNECT
RELAY
W
ATER
COOLER
115VAC
RECP.
115VAC
FAN
ARC LINK
WIRE
FEEDER
RECP.
S1
S6
C
ONNECTION
T
O WIRE
DRIVE
S1
S6
VOLT
SENSE
BOARD
MAIN
TRANSFORMER
S5
C
ONTACTOR AND PRECHARGE
C
ONTROL SIGNALS FROM
C
ONTROL BOARD
F
ROM CONTROL
B
OARD
2
4
V
A
C
1
15 VAC
5
2 VAC
2
30 VAC
4
0 VDC
4
0 VDC
40 VDC
40 VDC
ARC LINK
CONNECTION
TO
ROBOT
VOLTA GE SENSE
OUTPUT
C
AP.V/F
F
EEDBACK
CAP.V/F
FEEDBACK
IGBT DRIVE
FROM
CONTROL
BOARD
C
T CURRENT
T
O CONTROL
B
OARD
-15 V
+
15 V
+
5 V
+
5 V ARC LINK
+5V RS232
+15V SPI
STATUS THERMAL
LIGHT LIGHT
S
2 WORK
S
ENSE
L
EFT S.B.
CAP.V/F
RIGHT S.B.
CAP.V/F
S3
RS232
L
EFT CT
CURRENT
FB
C
U
R
R
E
N
T
F
B
A
RC LINK
IGBT
DRIVES
TO
LEFT
S.B.
TO
RIGHT
S.B.
6
7A
67B
SW1
BUS BOARD
RECTIFIER
CURRENT
TRANSDUCER
OUTPUT DIODES
D1 -D4
115 VAC
40 VDC
D
EVICE NET
V
OLTA GE SENSE SELECT
IGBT DRIVE
FROM
CONTROL
BOARD
+
5V SPI
RIGHT CT
CURRENT
FB
T
O FAN RELAY
CONTACTOR AND
PRECHARGE
CONTROL SIGNALS
6
5 VDC
WORK
TERMINAL
POWER WAVE 655/R
380-
415
440-
460
550-
575
+
ETHERNET/
A
A
HARMONIC
FILTER
C
POS
NEG
Auxiliary
Fan